Contents Index 7 - Peterbilt Trucks | Peterbilt Motors Company Engine Manuals/PACCAR... · 2014-09-29 · atthetimeofprinting.PACCAR reservestherighttomakechanges ... relieveallpressureintheair,oil,

Contents

Safety

Emergency

Controls

Driving

Maintenance

Information

Index

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2

3

4

5

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Contents

©2011 Paccar Inc - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or optional onthis vehicle. This manual may also include a description of features and equipment which are no longer available or werenot ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which arenot on this vehicle.

PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time withoutnotice and without incurring any obligation.

The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictlyprohibited without prior written authorization from PACCAR Inc.

Safety

IntroductionSafety Alerts . . . . . . . . . . . . . . 1-3Foreword . . . . . . . . . . . . . . . 1-5Important Reference Number . . . . . . . 1-6Illustrations. . . . . . . . . . . . . . . 1-7General Safety Instructions. . . . . . . . 1-7

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Introduction

Introduction

Safety Alerts

Please read and follow all of thesafety alerts contained in this manual.They are there for your protectionand information. These alerts canhelp you avoid injury to yourself, yourpassengers, and help prevent costlydamage to the vehicle. Safety alertsare highlighted by safety alert symbolsand signal words such as "WARNING","CAUTION", or "NOTE". Please do notignore any of these alerts.

WARNING

WARNING:

The safety alert following this symboland signal word provides a warningagainst operating procedures whichcould cause death or injury. They couldalso cause equipment or propertydamage. The alert will identify thehazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

WARNING: Do not carryadditional fuel containers inyour vehicle. Fuel containers,either full or empty, may leak,explode, and cause or feed afire. Do not carry extra fuelcontainers. Even empty onesare dangerous. Failure tocomply may result in death,

personal injury, equipment orproperty damage.

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Introduction

CAUTION

CAUTION:

The safety alert following this symboland signal word provides a cautionagainst operating procedures whichcould cause equipment or propertydamage. The alert will identify thehazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

CAUTION: Continuing tooperate your vehicle withinsufficient oil pressurewill cause serious enginedamage. Failure to complymay result in equipment orproperty damage.

NOTE

NOTE:

The alert following this symbol andsignal word provides importantinformation that is not safety relatedbut should be followed. The alertwill highlight things that may not beobvious and is useful to your efficientoperation of the vehicle.

Example:

NOTE: Pumping the acceleratorwill not assist in starting theengine.

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Introduction

Foreword

This manual contains information forthe correct operation and maintenanceof your PACCAR engine. Read andfollow all safety instructions. Referto the WARNING in the “GeneralSafety Instructions” beginning onpage 1-7. Keep this manual withthe equipment. If the equipment istraded or sold, give the manual tothe new owner. The information,specifications, and recommendedmaintenance guidelines in this manualare based on information in effectat the time of printing. PACCARreserves the right to make changesat any time without obligation. If youfind differences between your engineand the information in this manual,contact your local PACCAR AuthorizedRepair Location or write to PACCARc/o PACCAR Engines, PO Box 1518,Bellevue, WA 98009. The latesttechnology and the highest qualitycomponents were used to produce this

engine. When replacement parts areneeded, we recommend using onlygenuine parts from PACCAR.

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Introduction

Important ReferenceNumberFill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required.

Part Name Number

Engine Model

Engine Serial Number (ESN)

Oil Type (Use API CJ-4 oil only)

Filter Part Numbers:Air Cleaner Element

Lubricating Oil

Fuel (Use ultra-low sulfur diesel fuel only)

Coolant

Belt Part Numbers:

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Introduction

IllustrationsGeneral Information

Some of the illustrations throughoutthis manual are generic and will notlook exactly like the engine or partsused in your application.

The illustrations are intended to showrepair or replacement procedures.The procedure will be the same for allapplications, although the illustrationcan differ.

General Safety InstructionsImportant Safety Notice

WARNING: Improperpractices, carelessness,or ignoring any warningsmay cause death, personalinjury, equipment or propertydamage.

Before performing any repair, read andunderstand all of the safety precautionsand warnings. The following is a list ofgeneral safety precautions that mustbe followed to provide personal safety.Failure to follow these instructionsmay cause death or injury. Specialsafety precautions are included in theprocedures when they apply.

• Use the proper tool for manuallyrotating the engine. Do not attemptto rotate the crankshaft by pullingor prying on the fan. This practicecan cause death, personal injury,equipment damage, or damage to

the fan blades, causing prematurefan failure.

• Work areas should be dry, well lit,ventilated, free from clutter, loosetools, parts, ignition sources andhazardous substances.

• Wear protective glasses andprotective shoes when working.

• Do not wear loose-fitting or tornclothing. Remove all jewelry whenworking.

• Before beginning any repair,disconnect the battery (negative[-] cable) and discharge anycapacitors.

• Put a "DO NOT OPERATE" tag inthe operator’s compartment or onthe controls.

• Allow the engine to cool beforeslowly loosening the coolant fillercap to relieve the pressure fromthe cooling system.

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Introduction

• Always use blocks or properstands to support the vehicleor vehicle components beforeperforming any service work.Do not work on anything that issupported only by lifting jacks ora hoist.

• Before removing or disconnectingany lines, fittings, or related items,relieve all pressure in the air, oil,fuel, and cooling systems. Remainalert for possible pressure whendisconnecting any device from asystem that contains pressure.High pressure oil or fuel can causedeath or personal injury.

• Always wear protective clothingwhen working on any refrigerant(Freon) lines and make sure thatthe workplace is in a well ventilatedarea. Inhalation of fumes cancause death or personal injury.To protect the environment,liquid refrigerant systems mustbe properly emptied and filled

using equipment that preventsthe release of refrigerant gas.Federal law requires capturingand recycling refrigerant.

• When moving or lifting any heavyequipment or parts, make sureto use proper techniques andassistance. Ensure all liftingdevices such as chains, hooks, orslings are in good condition andare of the correct load capacity.Make sure any lifting devices arepositioned correctly.

• Corrosion inhibitors and lubricatingoils may contain alkali. Do not getthe substance in eyes and avoidprolonged or repeated contactwith skin. Do not swallow. Incase of contact, immediately washskin with soap and water. In caseof harmful contact, immediatelycontact a physician. Always keepany chemicals OUT OF REACHOF CHILDREN.

• Naptha and Methyl Ethyl Ketone(MEK) are flammable materialsand must be used with caution.Follow the manufacturer’sinstructions to ensure safety whenusing these materials. Alwayskeep any chemicals OUT OFREACH OF CHILDREN.

• When working on the vehicle,be alert for hot parts on systemsthat have just been turned off,exhaust gas flow, and hot fluids inlines, tubes, and compartments.Contact with any hot surface maycause burns.

• Always use tools that are in goodcondition. Make sure you havethe proper understanding of howto use the tools before performingany service work. Use onlygenuine replacement parts fromPACCAR.

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Introduction

• Always use the same fastenerpart number (or equivalent) whenreplacing items. Do not usea fastener of lesser quality ifreplacements are necessary.

• Do not perform any repair whenimpaired, tired, fatigued or afterconsuming alcohol or drugs thatcan impair your functioning.

• Some state and federal agenciesin the United States of Americahave determined that used engineoil can be carcinogenic and cancause reproductive toxicity. Avoidinhalation of vapors, ingestion,and prolonged contact with usedengine oil.

• Coolant is toxic. If not reused,dispose of coolant in accordancewith local environmentalregulations.

• California Proposition 65 Warning- Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

• The catalyst substrate locatedin the Diesel Particulate Filtercontains Vanadium Pentoxide.Vanadium Pentoxide has beendetermined by the State ofCalifornia to cause cancer. Alwayswear protective clothing and eyeprotection when handling thecatalyst assembly. Dispose of thecatalyst in accordance with localregulations. If catalyst materialgets into the eyes, immediatelyflood eyes with water for aminimum of 15 minutes. Avoidprolonged contact with skin. Incase of contact, immediately washskin with soap and water. In caseof harmful contact, immediatelycontact a physician.

CAUTION: Corrosivechemicals can damagethe engine. Do not usecorrosive chemicals on theengine. Failure to complymay result in equipment orproperty damage.

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EMERGENCY

WHAT TO DO IF...You Need Roadside Assistance. . . . . . 2-3Stop Engine Lamp Turns On . . . . . . . 2-3Engine Oil Pressure Lamp Turns On. . . . 2-4Check Engine Lamp Turns On . . . . . . 2-5Engine is Overheating . . . . . . . . . . 2-5

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WHAT TO DO IF...

WHAT TO DO IF...

You Need RoadsideAssistance

Call toll-FREE to talk to someone atthe PACCAR Customer Center. Thetoll-FREE telephone number is locatedon the windshield decal.

• Open 24-7-365 days a year

• They can help you get roadsideassistance.

• They have a custom mappingsystem which locates authorizedPACCAR engine dealers andIndependent Service Providers(ISPs) near you and lists typesof services offered, hours ofoperation and contact information.

• They can assist with jump andpull starts, tires, trailers, fines andpermits, chains, towing, hazardousclean-up, out of fuel (roadside),

mechanical repairs and preventivemaintenance services.

• They have multilingual agents andaccess to a translation serviceto ensure quality assistancefor customers who speak anylanguage.

• They can’t answer your warrantyquestions but can get you incontact with an authorized dealerwho can.

• The PACCAR Customer Centerservice is FREE.

Stop Engine Lamp Turns OnStop Engine Lamp - If theStop Engine warning lampilluminates, it means youhave a serious engine systemproblem.

WARNING: This should beconsidered an emergency.You should stop the vehicleas safely as possible andturn OFF the ignition. Thevehicle must be serviced andthe problem corrected beforedriving again. Failure to doso may result in personalinjury, severe engine damage,equipment or propertydamage.

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WHAT TO DO IF...

Engine Oil Pressure LampTurns On

Engine Oil Pressure Gauge- It is important to maintainoil pressure within acceptablelimits. If oil pressure dropsbelow the minimum psi aRed Warning Lamp on the oilpressure gauge and the StopEngine Lamp will come ON.

CAUTION: Continuing tooperate your vehicle withinsufficient oil pressure maycause severe engine damage,equipment or propertydamage.

• If the oil pressure fails torise within 10 secondsafter the engine starts,stop the engine anddetermine the cause.

• See Lubricating OilSystem on page 5-11, for

the correct oil pressureranges for your vehicle’sengine.

• If the oil pressuresuddenly drops, or theaudible alarm and engineoil pressure warning lightcome on while driving, dothe following:

1. Slow down carefully.

2. Move a safe distance offthe road and stop.

3. Place the transmissionin neutral and set theparking brake. (SeeParking Brake Valveand OPERATING THETRANSMISSION inyour vehicle Operator’sManual, for transmissionshifting and parking brakeinformation.)

4. Turn OFF the engine.

5. Turn ON the emergencyflasher and use otherwarning devices to alertother motorists.

6. Wait a few minutes toallow oil to drain into theengine oil pan, and thencheck the oil level. (SeeInspection of the EngineOil Level on page 5-4.)

7. Add oil if necessary. If theproblem persists, contactan authorized PACCARengine dealer as soon aspossible.

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WHAT TO DO IF...

Check Engine Lamp TurnsOn

Check Engine Lamp - Turnson when a problem exists, butthe vehicle can still be safelydriven. Vehicle should beserviced to correct the problembut the situation should not beconsidered an emergency.

Engine is Overheating

CAUTION: The coolingsystem may overheat if theengine coolant is at theminimum level. A suddenloss of coolant, caused bya split hose or broken hoseclamp could also lead to anoverheat condition. Alwaysinspect to ensure hoses andclamps are not cracked, worn,or loose. Failure to complymay result in equipment orproperty damage.

NOTE: The system may alsotemporarily overheat duringsevere operating conditionssuch as:

• Climbing a hill on a hot day.

• Stopping afterhigh-speed/high-loaddriving.

• Debris blocking air flowthrough the cooling module(radiator).

NOTE: If the engine coolanttemperature warning lampcomes on and the audible alarmsounds showing an overheatcondition, or if you have anyother reason to suspect theengine may be overheating,DO NOT TURN OFF THEENGINE unless a low waterwarning device indicates a lossof coolant. Follow these steps:

• Reduce engine speed orstop. When stopped, placethe transmission in neutraland set the parking brake.See the vehicle operator’smanual for instructions ontransmission shifting andparking brake information.

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WHAT TO DO IF...

• Check to ensure that theoil pressure gauge readsnormal.

• Increase the engine speedto 1,100 to 1,200 rpmmaximum for 2-3 minutes.

• Monitor the enginetemperature. After thetemperature returns tonormal, allow the engineto idle 3–5 minutes beforeshutting it off. This allowsthe engine to cool graduallyand uniformly.

• If the overheating camefrom severe operatingconditions, the temperatureshould have cooled by thistime.

• Check the coolant level atthe cooling module surgetank.

WARNING: To reducethe chance of personalinjury and/or vehicledamage caused by engineoverheating, never leavethe engine idling when thevehicle is unattended. If theengine overheats, immediateaction is required to correctthe condition. Continuedunattended operation of theengine, even for a short time,may result in serious enginedamage or a fire. Failure tocomply may result in death,personal injury, equipment orproperty damage.

WARNING: Removing thesurge tank fill cap whilethe engine is hot can bedangerous. Never removethe surge tank cap while theengine is still hot; you couldbe badly burned. Failure tocomply may result in death,

personal injury, equipment orproperty damage.

• Scalding steam and fluidunder pressure mayescape and cause seriouspersonal injuries.

• Wait until the coolanttemperature is below122°F (50°C).

• Protect your face, hands,and arms by covering thecap with a large, thickrag to protect againstescaping fluid and steam.

• Carefully and slowlyturn the cap one turn toallow excess pressure toescape, then push downand turn for final removal.See the vehicle operator’smanual for instructionson checking and fillingthe cooling module surgetank.

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WHAT TO DO IF...

CAUTION: Do not allowyour engine to idle, at lowRPMs (400–600 rpm), longerthan 5 minutes. Prolongedperiods of idling after theengine has reached operatingtemperatures can decreaseengine temperature and couldcause engine damage frominadequate lubrication. Thenormal torsional vibrationsgenerated can also causetransmission wear. An idleshutdown feature, availableon PACCAR engines, canbe programmed to shutthe engine down after aperiod of low idle operationwith no driver activity. Aflashing warning lamp willinform the driver of animpending shutdown. Ifthe truck is equipped withPTO equipment, the engineshutdown system can bedeactivated when the PTO is

operational; however, engineidle periods should notexceed 5 minutes wheneverpossible. Failure to complymay result in equipment orproperty damage.

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Controls

Operating InstructionsEngine Warning Lamps . . . . . . . . . 3-3Engine Operating Range. . . . . . . . . 3-6Engine Braking System . . . . . . . . . 3-6

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Operating Instructions


Engine Warning LampsGeneral Information

The following engine warning lampscover only the lamps controlled by theengine’s Electronic Control Module(ECM). Please refer to the vehicleoperator’s manual for additionalwarning lamp information.

Check Engine Lamp

The check engine warning lamp willilluminate when a problem exists,but the vehicle can still be safelydriven. The vehicle should be servicedto correct the problem, but thesituation should not be considered anemergency.

The lamp will also illuminate when aDPF regeneration or addition of DieselExhaust Fluid is required. Anotherfunction of the check engine lamp is towarn the operator of an impending idleshutdown. When the idle shutdowntimer is 30 seconds from expiring, theengine ECM begins flashing the checkengine warning lamp once per second.When the timer expires, the ECM will

turn off the warning lamp and shutdown the engine.

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Stop Engine Lamp

The stop engine warning lamp willilluminate, and an audible tone willsound, when a major engine problemexists.

WARNING: This should beconsidered an emergency.You should stop the vehicleas safely as possible andturn OFF the ignition. Thevehicle must be servicedand the problem correctedbefore driving again. Failureto comply may result inpersonal injury, severeengine damage, equipment orproperty damage.

For engines with the engine protectionshutdown feature enabled, thestop engine lamp will begin toflash 30 seconds before the engineautomatically shuts down. Thewarning lamp alerts the operator to theimpending shutdown.

The lamp will also illuminate whenthe Diesel Exhaust Fluid (DEF) tankis almost empty or the soot level inthe DPF is at full capacity. At thislevel warning, regeneration cannot beperformed and engine power will bederated.

Diesel Particulate Filter (DPF)Warning Lamp

DPF Warning Lamp

Refer to Engine AftertreatmentSystems Operator’s Manual foradditional information.

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High Exhaust System Temperature(HEST) Warning Lamp

HEST Warning Lamp


Check Engine Lamp (CEL)

Check Engine Lamp


Diesel Emission Fluid (DEF) Lamp

Diesel Emission Fluid (DEF) Lamp


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Engine Operating RangeGeneral Information

CAUTION: Operating theengine at full throttle belowpeak torque will shortenengine life to overhaul,can cause serious enginedamage, and is consideredengine abuse. Do notoperate the engine at fullthrottle operation below peaktorque rpm for more than 30seconds. Failure to complymay result in equipment orproperty damage.

PACCAR engines are designed tooperate at full throttle under momentaryconditions down to peak torque enginespeed. This is consistent withrecommended operating practices.

CAUTION: Operating theengine beyond the maximumengine speed can causesevere engine damage. Useproper operating techniquesfor the vehicle to preventengine overspeed. Themaximum engine speedspecification is listedin the “General EngineSpecifications” on page 5-10.Failure to comply may resultin equipment or propertydamage.

Engine Braking System

WARNING: Do not operatethe engine compressionbrake when driving/operatingyour vehicle bobtail or witha loaded or unloaded traileron road surfaces with poortraction (wet, icy, or snowcovered roads) or in heavytraffic. Braking caused bythe normal operation ofthe engine compressionbrake could cause you tolose control of the vehicleresulting in an injury accident.Failure to comply may resultin death, personal injury,equipment or propertydamage.

WARNING: The servicebrakes must be used in anemergency. The enginecompression brake alonemight not stop the vehicle

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fast enough to preventan accident. The enginecompression brake is NOTintended as the primary brakefor the vehicle, nor is it anemergency brake. The enginecompression brake onlyhelps the service brakes byusing engine backpressureto slow the drivetrain. Usethe service brakes for quickstops. You could be seriouslyinjured if you relied onlyon the engine compressionbrake to stop the vehicle in anemergency. Failure to complymay result in death, personalinjury, equipment or propertydamage.

WARNING: Do not usethe compression brakewhen operating on roadsurfaces with poor traction(such as wet, icy, or snowcovered roads or gravel).

Compression brakes cancause the wheels to skid ona slippery surface. You couldlose control of the vehicleand/or jackknife if the wheelsbegin to skid, resulting in anaccident. Failure to complymay result in death, personalinjury, equipment or propertydamage.

NOTE: If your vehicle isequipped with anti-lockbrakes (ABS), operation ofthe compression brake (if turnedON) may be interrupted if theABS system detects wheel slipdue to operation on slipperysurfaces.

An engine compression brake isstandard on the PACCAR MXengine. When activated, the enginecompression brake creates a brakingeffect on the drive wheels. Thisdevice uses engine power to slow

the vehicle down. Because it canhelp keep your vehicle’s brakes fromoverheating, it can save wear and tearon the service brakes. However, theengine compression brake is not anemergency brake.

Ideally (on normal road surfaces),you should slow your vehicle with thecompression brake (where permittedby law) and use the service brakes onlyfor stopping completely. Operating thisway will greatly prolong the life of theservice brakes.

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Compression Brake

With the compression brake switchON, the brake automatically creates itsbraking effect when you remove yourfoot from the accelerator pedal.

The brake switch is located on theaccessory dash panel. It controlswhether the brake is ON (ready to slowthe vehicle down) or OFF (no brakingaction).

• Do not use the enginecompression brake to slowthe vehicle down when you arebobtailing or pulling an emptytrailer.

• Make sure the brake is OFF beforestarting the engine.

• After the engine is started, warmedup, and you are ready to get underway, turn the engine compressionbrake switch ON for added brakingeffect.

NOTE: If your vehicle isequipped with the EatonVorad® system, operation ofthe compression brake may beautomatically activated.

Compression Brake Controls

Two (2) switches on the dash panelcontrol the engine compression brake.A master switch turns the system ONor OFF. A second switch, locatednext to the master switch, controlsthe braking effect. This switch allowsyou to choose progressively strongerbraking to slow the vehicle down.

Engine compression brake controlsinclude:

• On/Off switch.

• 3-position selector switch.

• Clutch switch.

• Throttle sensor.

• Service brake pressure switch.

• Eaton Vorad® Anti-Lock BrakingSystem

Engaging conditions for the enginecompression brake are:

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• Engine speed must be above1,000 rpm.

• Coolant temperature must beabove 59°F (15°C).

Deactivation conditions for the enginecompression brake are:

• Accelerator pedal is depressed.

• Clutch pedal is depressed.

• Engine speed falls below 800 rpm.

• ABS control is active.

• Engine ECM recognizes a systemproblem.

CAUTION: Operating theengine with a compressionbrake that will notautomatically deactivate(i.e. when the dash switch isoff, clutch pedal is depressedor throttle is applied) willcause severe internal enginedamage. Do not operate the

engine if the compressionbrake will not deactivate.Failure to comply may resultin equipment or propertydamage.

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Engine Compression Brake LevelSwitch Operation

There are 2 switches that control yourvehicle’s engine compression brake.One switch turns the system on/off andthe second switch controls the brakinglevel. These switches are located onthe dash switch panel.

For the 3-position engine compressionbrake level switch, there will be 100%engine braking when the switch is inthe up (HIGH) position. In the middle(MEDIUM) position, there will be 66%engine braking. In the down (LOW)position there will be 33% enginebraking.

With the compression brake switchON, the compression brake will beengaged when the service brake isapplied.

If the cruise control is operated inconjunction with the compressionbrake, the compression brake will

engage to maintain the cruise setspeed.

On/Off Switch Symbol

Compression Brake Level SwitchSymbol

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Driving

Operating InstructionsGeneral Information . . . . . . . . . . . 4-3Normal Starting Procedure . . . . . . . . 4-4Cold Weather Starting . . . . . . . . . . 4-5Starting Procedure After ExtendedShutdown or Oil Change . . . . . . . . 4-5

Operating the Engine . . . . . . . . . . 4-6Engine Shutdown . . . . . . . . . . . . 4-6Electromagnetic Interference (EMI) . . . . 4-6

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General Information

Correct care of your engine will resultin longer life, better performance, andmore economical operation.

Follow the daily maintenance checkslisted in “Maintenance Schedule” onpage 5-4.

Check the engine oil pressure andengine coolant gauges, warning lights,and other gauges daily to make surethey are operational.

WARNING: Combustiblevapors near the air intakesystem could be ingestedinto the engine, causingthe engine to suddenlyaccelerate and overspeed.This condition could resultin operator losing control ofthe vehicle if an unexpected

increase in engine rpmoccurs. Combustible vaporscould also cause a fire. Donot operate your vehicle inan area where combustiblechemicals or vapors may bepresent. Failure to complymay result in death, personalinjury, equipment or propertydamage.

IT IS THE RESPONSIBILITY OFTHE OWNER AND OPERATOR TOOPERATE THE VEHICLE IN A SAFEENVIRONMENT.

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Normal Starting ProcedureStarting

Ensure the parking brake is set ONand the transmission shift lever is inneutral. For automatic transmissionsthat have park position, place the shiftlever in park.

With the accelerator pedal in the idleposition, turn the ignition key to theSTART position.

NOTE: Release the key after 10seconds if the engine does notstart. Then wait 10 seconds andtry again.

NOTE: If the engine is running,do not increase engine speed(rpm) or operate the vehicle untilthe low oil pressure warninglamp turns off.

With the key in the ON position, theengine warning lamps will come onmomentarily and then go out. Theengine warning lamps include:

1. Check engine lamp; yellow incolor.

2. STOP engine lamp; red in color.

3. Diesel Particulate Filter (DPF)status indicator; yellow in color.

4. High Exhaust System Temperature(HEST); amber in color.

CAUTION: Engaging thestarter motor for more than30 seconds in any fifteenminute period may cause it to

overheat and can damage thestarter motor.

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Cold Weather StartingGeneral Information

Follow the “Normal Starting Procedure”on page 4-4.

Refer to the vehicle operator’s manualinstructions for any additional coldweather starting procedures.

If starting a cold engine, slowlyincrease the engine speed. Thisprovides adequate lubrication to thebearings and gives ample time to allowthe oil pressure to stabilize.

The use of cold starting aids arenot recommended for ambienttemperatures above 0° F (-18° C).

If an engine must idle for an extendedperiod of time, it should be done ata fast idle (1000 rpm maximum) atcoolant temperatures below 150° F(70° C).

For coolant temperatures above 150°F (70° C), use a low gear and drive

at moderate engine speed until theengine coolant has reached operatingtemperature. Do not let the engine idlelonger than necessary.

CAUTION: Do not operatethe engine at low idle forlong periods of time whenthe coolant temperature isbelow the normal operatingrange. This could result inthe following:

• Fuel dilution of thelubricating oil

• Carbon buildup in thecylinder

• Sticking of the valves inthe cylinder head

• Reduced performance

• Damage to aftertreatmentcomponents

Starting Procedure AfterExtended Shutdown or OilChangeGeneral Information

Follow the “Normal Starting Procedure”on page 4-4.

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Operating the EngineNormal

Monitor the oil pressure and coolanttemperature gauges frequently. Referto “Lubricating Oil System” on page5-11 and “Cooling System” on page5-12 for recommended operatingpressures and temperatures. Shutoff the engine if any pressure ortemperature does not meet thespecifications.

Engine ShutdownBefore Stopping the Engine

NOTE: Do not shut off theengine immediately. A hotengine stores a great amount ofheat and it does not cool downimmediately after it is shut off.Always cool the engine downbefore shutting it off. You willgreatly increase its service life.

Idle the engine at 1,000 rpm for 4minutes. Then low idle for 30 secondsbefore shutdown. This will allowcirculating coolant and lubricating oilto carry heat away from the cylinderhead, valves, pistons, cylinder liners,turbocharger, and bearings. This wayyou can prevent engine damage thatmay result from uneven cooling.

ElectromagneticInterference (EMI)General Information

If not installed correctly, some vehicleaccessories (CB radios, mobiletransmitters, etc.) can generate anduse radio frequency energy that maycause electromagnetic interference(EMI) between the accessory andthe electronic controlled fuel system.Under these conditions, PACCARis not liable for any performanceproblems with either the fuel system orthe accessory. EMI is not consideredby PACCAR to be an engine failureand therefore is not warrantable.

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System EMI Susceptibility

PACCAR products are designedand tested for minimum sensitivityto incoming electromagnetic energy.The fuel system EMI susceptibilityhas been designed with a hightolerance against EMI and in mostnormal circumstances, if not all,electromagnetic energy-emittingdevices that meet the FederalCommunications Commission legalrequirements should cause nointerference.

System EMI Radiation Levels

Electronic components are requiredto pass various PACCAR and industryEMI specifications. Our testinghas shown that when the engine isproperly installed and maintained, itwill not interfere with properly installedonboard communication equipment.

If any interference condition is noticed,follow these suggestions to reduce theamount of EMI:

1. Locate the accessory receivingantenna further away.

2. Check with the accessory supplierrepresentative in your area to:

° Accurately calibrate theaccessory for properfrequency, power output,and sensitivity.

° Determine the optimumantenna location by obtainingantenna reflective energy datameasurements.

° Ensure that the optimumantenna type and mountingarrangement is being used.

° Ensure the accessoryequipment is properlyconstructed for maximumfiltering to reject incomingelectromagnetic noise.

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Maintenance

Maintenance GuidelinesOverview . . . . . . . . . . . . . . . 5-3Maintenance Schedule . . . . . . . . . 5-4

Maintenance SpecificationsGeneral Engine Specifications . . . . . 5-10Lubricating Oil System. . . . . . . . . 5-11Cooling System. . . . . . . . . . . . 5-12Filter Specifications . . . . . . . . . . 5-13Fuel Recommendations . . . . . . . . 5-13Warranty and the Use of Biodiesel Fuel . 5-15Lubricating Oil Recommendations andSpecifications . . . . . . . . . . . 5-16

Coolant Recommendations andSpecifications . . . . . . . . . . . 5-17

Maintenance ProceduresOil Pan Drain Plug . . . . . . . . . . 5-20Inspection of the Engine Oil Level . . . . 5-20Topping Up the Engine Oil . . . . . . . 5-21

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Maintenance

Replacing Engine Oil Filters . . . . . . 5-22Replacing Fuel Filter . . . . . . . . . 5-26Replacing Coolant Filter . . . . . . . . 5-29Emergency Repairs . . . . . . . . . . 5-30

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Maintenance Guidelines


OverviewGeneral Information

PACCAR recommends that theengine be maintained according to themaintenance schedule in this section.

If the engine is operating in ambienttemperatures below 0°F (-18°C)or above 100°F (38°C), performmaintenance at shorter intervals.Shorter maintenance intervals are alsorequired if the engine is operated in a

dusty environment or if frequent stopsare made.

Some of these maintenanceprocedures require special toolsor must be completed by qualifiedpersonnel. Contact your localPACCAR authorized repair location fordetailed information.

If your engine is equipped witha component or accessory notmanufactured by PACCAR Inc, referto the component manufacturer’smaintenance recommendations.

Oil Drain Intervals

Oil drain interval recommendations arebased on vehicle application or engineduty cycle. PACCAR recommendsthe use of high quality lubricating oilas indicated in the Lubricating OilRecommendations on page 5-16 in theMaintenance Specifications Section.

Oil Drain Interval Guidelines

Severe DutyVocational**

Normal DutyLine Haul

Fuel ConsumptionMiles per GallonKilometers per Liter

Less than 6 MPGLess than 2.6 km/L

6 MPG or greater2.6 km/L or greater

Gross Vehicle Weight More than 80,000 lbMore than 36,300 kg

80,000 lb or less36,300 kg or less

Oil Drain Interval 25,000 miles/40,000 km800 hours or 12 months

40,000 miles/64,000 km1200 hours or 12 months

**Vocational vehicle applications include: Agriculture, Concrete Mixers, Construction, Crane, Dumps, Emergency/Fire, Heavy Equipment, Loggers,Mining, Oil Field, Refuse, Pick-up & Delivery, Snowplows, and Wrecker

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Maintenance ScheduleGeneral Information

Perform maintenance at whicheverinterval occurs first. At each scheduledmaintenance interval, perform allprevious maintenance checks that aredue for scheduled maintenance.

NOTE: This maintenanceschedule is for a Normal DutyCycle engine operation. SevereDuty / Vocational applicationswill need to adjust mileage,kilometer, hour, or time intervalbased on the Oil Drain IntervalGuidelines listed above.

Daily or Refueling – MaintenanceCheck

• Engine Lubrication Oil Level -Check/CorrectTo check engine oil level, park

vehicle on level ground and wait 15minutes after shutting off engine.

° Remove dipstick and wipe itoff with a clean, lint free rag.

° Reinsert dipstick all the way inand pull it out again to checkoil level.

° Correct oil level is betweenthe low (L) and high (H) markson the dipstick.

• Fuel – Water Separator (ifinstalled) – Drain trapped water

• Air Intake Piping – Inspect

° Hose/Pipe condition –deterioration/signs of leaking

° Hose clamps for tightness

° Clearance to othercomponents

° Check Air Restriction Gauge

• Aftertreatment Exhaust Piping –Inspect

° Cracks

° Clearance to othercomponents (i.e. electricalharnesses, etc.)

° Hose/pipe condition –deterioration/signs of leaking

• Cooling Fan – Inspect

° Cracks


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• Engine Coolant Level –Check/Correct

With the engine off andtemperature cool:

° Check coolant level. It shouldbe visible through the clearplastic surge tank.

° Add coolant as necessary byremoving the pressure cap onthe neck of the surge tank orsight glass.

° Replacement or top upcoolant should have the sameantifreeze concentration andcorrosion inhibitor contentas the original coolant in thecooling system.

° Always dilute antifreeze tothe correct concentrationbased on freeze protectionbefore adding it to the coolingsystem. Adding or using 100%

antifreeze in a cooling systemmay result in cooling systemplugging and overheatingproblems.

• Diesel Emission Fluid (DEF) level– Check/Top Up:

NOTE: It is recommendedto top up DEF whenrefueling. See EngineAftertreatment SystemsOperator’s Manual for DEFinformation.

• Check for any signs of fluidleaks

• Ensure all access caps/covers areinstalled and tight.

Every 20,000 mi (32,000 km), 600Hours, or 6 Months - MaintenanceCheck

• Air Cleaner Restriction -Check/Correct

° Service filter element whenair cleaner restriction gauge(option) locks in the extremehigh position.

° Hose/pipe condition -deterioration/signs of leaking

° Hose clamp torque

• Charging/Cranking System-Check

° Inspect electricalharness/cables for looseconnections, corrosion,chafing, and broken retentionclips.

• Charge Air Piping - Check/Correct


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° Hose clamps for tightness


• Charge Air Cooler - Check/Correct

° Cracked tubes or header

° Clogged fins/tubes



• Drive Belts - Check/Correct

° Belt condition - signs ofwear/deterioration

° Belt alignment

• Fan Belt Tensioner -Check/Correct

° Mounting bolt torque

° Tensioner maintains properbelt tension

**Initial Only 40,000 mi (64,000km), 1,200 Hours, or 12 months -Maintenance Check

• Valve Clearance - Adjust**(See note 3 below)

• Valve Cover Gasket Seal -Replace

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Every 40,000 mi (64,000 km), 1,200Hours, or 12 months - MaintenanceCheck

• Fuel Filter, Canister and Spin-onType - Replace

• Lubricating Oil - Change

• Lubricating Oil Filters - Change

• Cooling System Antifreeze Check

° Coolant level

° Coolant Protection

• Batteries - Check

° Battery Cables andConnections – Check

° Battery condition – electrolytelevel, cracks, signs of leaking,overcharging

° Battery hold-downs fortightness

° Battery box mounting bolttorque

Every 80,000 mi (128,000 km), 2,400Hours, or 2 Years - MaintenanceCheck

• Radiator Hoses - Check

° Hose condition -deterioration/signs of leaking


• Crankshaft Vibration Damper -Check

° Damper for cracks, nicks,Leakage

° Damper fastener torque

• Air Compressor Carbon Buildup -Check/Correct

Every 160,000 mi (256,000 km),4,800 Hours – Maintenance Check

• Cooling system antifreeze check

° Coolant level

° Coolant protection

° Replace coolant filter

• Aftertreatment Fuel Injector –Clean

• Exhaust System - Change

° Replace exhaust flex pipe(s)

• Valve Clearance - adjust

• Valve cover gasket seal - replace

• Engine mounting bolts - check

° Check bolt torque

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• Aftertreatment Diesel ExhaustFluid (DEF) Dosing Unit (DEFModule) Filter – Replace

• Aftertreatment Diesel ParticulateFilter (DPF) cleaning, usingDPF cleaning machine**(See note 4 below)


• Crankcase Ventilation – Replace

Every 750,000 mi (1,200,000km), 22,000 Hours, or 6 years –Maintenance Check

• Change extended life coolant**(See note 1 below)

NOTE:

1. A heavy-duty extended lifecoolant (ELC) that meetsASTM D 6210 chemicalcomposition specificationsmust be used. The changeinterval is 750,000 miles(1,200,000 km) or 22,000hours on-road use (8years or 15,000 hoursoff-highway use) on initialfill with no extender added.The change interval is1,000,000 miles (1,600,000km)/20,000 hours/8 yearswith an extender additionat 500,000 miles (800,000km)/10,000 hours/4 years.Antifreeze is essential

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for freeze, overheat, andcorrosion protection. Theuse of supplemental coolantadditives (SCAs) is notrecommended.

2. Follow the manufacturers’recommendedmaintenance proceduresfor the starter, alternator,batteries, electricalcomponents, radiator,air compressor, air cleaner,refrigerant compressor, andfan clutch.

3. Reset valve lash, if needed,to nominal specifications.

4. The aftertreatment DPFclean/replace intervalis based on the use oflubricating oils that meet theSAE 15W40 (API CJ-4) oilspecification.

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Maintenance Specifications

MaintenanceSpecifications

General EngineSpecificationsHorsepower See EPA Label on top of the valve coverFiring Order 1, 5, 3, 6, 2, 4Crankshaft Rotation (viewed from front of engine) ClockwiseDisplacement 784 CID (12.9 liters)Bore and Stroke 5.12 in. (130 mm) × 6.38 in. (162 mm)

Dry Weight 2,640 lbIdle Speed Approximately 650 rpmMaximum Loaded Engine Speed 1,900 rpm

Maximum Governed No-Load Engine Speed 2,200 rpm

Maximum Engine Compression Brake Speed 2,100 rpm

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Lubricating Oil SystemAt Low Idle (minimum allowable) 27 psi (187 kPa) at 191°F (88°C) oil temperatureOil PressureAt Road Speed 900-1,900 rpm (minimumallowable)

40 psi (276 kPa) at 215°F (102°C) oil temperature

Regulated Oil Pressure 72 psi (496 kPa) at 223°F (106°C) oil temperatureTotal System Capacity (Oil Pan and New Oil Filters) 42 qt (40.0 liters)

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Cooling SystemCoolant Capacity Approximately 14 to 15 gallons (53 to 57 liters) depending on chassis

model and cab/ sleeper heater optionsMinimum Recommended Pressure Cap 15 psi (103 kPa)Maximum Top Tank Coolant Temperature 121°F (49°C) above outside temperature

WARNING: Coolant is toxic.Do not get the fluid in eyes. Ifcontact with the eyes occurs,flood eyes with large amountsof water for 15 minutes.Avoid prolonged or repeatedcontact with skin. In case ofcontact, immediately washskin with soap and water.Do not take internally. Ifswallowed, seek immediatemedical attention. Do notinduce vomiting. Failure tocomply may result in death,personal injury, equipment orproperty damage.

NOTE: Coolant is harmful to theenvironment. Unused coolantmust be stored as a toxichazardous material in leakproofcontainers. Used coolant mustbe processed as industrialchemical waste. Please followHAZMAT guidelines with bothused and unused coolants.

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Filter SpecificationsGeneral Information

PACCAR is not responsible forproblems caused by non-genuine filtersthat do not meet PACCAR performanceor durability requirements.

Contact your local PACCAR authorizedrepair location for specific partnumbers.

Fuel Recommendations

WARNING: The use of dieselfuel that has been mixedwith other fuels may causean explosion. Do not mixgasoline, alcohol, or gasoholwith diesel fuel. Make sureyou know your fuel sourceand use the recommendeddiesel fuel as indicated in thissection of the manual. Failureto comply may result in death,personal injury, equipment orproperty damage.

CAUTION: Dirt or water in thefuel system can cause severedamage to both the fuel pumpand the fuel injectors. Dueto the precise tolerances ofdiesel injection systems, it isextremely important that thefuel be kept clean and freeof dirt or water. Know yourfuel source and make sure all

steps are taken for dispensingor using clean fuel in yourvehicle. Failure to complymay result in equipment orproperty damage.

CAUTION: Lighter fuelcan reduce economy orpossibly damage fuel systemcomponents. Lighter fuelstypically do not have enoughlubricity elements in thefuel to properly lubricatethe fuel injection system.Be sure you follow thefuel recommendations asindicated in this section ofthe manual. Failure to complymay result in equipment orproperty damage.

CAUTION: Using diesel fuelsblended with lubricantsmay cause damage to yourexhaust aftertreatmentsystem. Service intervals for

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aftertreatment systems willbe reduced. Do not use dieselfuel blended with lubricatingoil in engines equipped withan aftertreatment system.Failure to comply may resultin equipment or propertydamage.

CAUTION: Do not usehigh-sulfur diesel fuel asit will damage the exhaustaftertreatment system. Also,the engine will not meetemission regulations. Useonly ultra-low-sulfur diesel(ULSD) fuel. Failure to complymay result in equipment orproperty damage.

CAUTION: If ultra-low-sulfurdiesel fuel is not used,the engine may not meetemission regulations, anddamage may occur to theexhaust aftertreatment

system. The use ofhigh-sulfur diesel fuelwill damage the exhaustaftertreatment systemand impact the engineemission. Ultra-low-sulfurdiesel fuel is required forcorrect operation of theaftertreatment system. Theengine has been optimizedfor use with an aftertreatmentsystem to meet the 2010 U.S.Environmental ProtectionAgency regulations. Failureto comply may result inequipment or propertydamage.

NOTE: PACCAR recommendsthat the cetane number of dieselfuel be a minimum of 45 forengines that are expected tooperate at temperatures below32°F (0°C) and a minimum of 42for engines that are operated attemperatures above 32°F (0°C).

NOTE: Using diesel fuel witha lower-than-recommendedcetane number can causehard starting, instability, andexcessive white smoke. Tomaintain satisfactory operationat low ambient temperatures, itis important to specify diesel fuelof the correct cetane number.

NOTE: PACCAR requiresall permissible fuels to haveadequate fuel lubricity. Lubricitycan be determined by ASTM,specification D6079, ISO 12156,High Frequency ReciprocatingRig (HFRR) in which the fuelmust have a wear scar diameterof 0.02 in. (0.5 mm) or less.

NOTE: The use ofUltra-Low-Sulfur diesel fuelis required for this enginein order to meet emissionregulations and to preventdamage to the engine and

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exhaust system. The use ofother grades of diesel fuelsother than Ultra-Low-Sulfurdiesel fuel will be considereda use of incorrect fuel forthe engine. PACCAR is notresponsible for failures causedby the use of incorrect fuel, oilor catalytic reagent or by water,dirt or other containments in thefuel or catalytic reagent.

Warranty and the Use ofBiodiesel FuelPACCAR Inc approves the use ofbiodiesel fuel blends up to 5% byvolume in diesel fuel that meets all ofthe following three conditions:

• The biodiesel used in the blendmeets ASTM Standard D 6751 orEN 14214 specifications.

• The biodiesel used in the blendis sourced from a BQ-9000Accredited Producer.

• The finished blend meets the fuelproperties of ASTM Standard D975 or EN 590 specifications.

The use of approved biodiesel fueldoes not affect the PACCAR enginewarranty. Failures caused by the useof nonapproved biodiesel fuels or otherfuel additives that are of unacceptablequality or do not meet specifiedindustry standards are not consideredas defects of parts or workmanship

by PACCAR and therefore will notbe covered by the PACCAR enginewarranty.

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Lubricating OilRecommendations andSpecificationsGeneral Information

CAUTION: Extending the oiland filter change intervalbeyond the recommendationswill decrease the enginelife due to factors such ascorrosion, deposits, andwear. Engine oil filterscapture dirt and removedeposits from the oil toprolong the life of internalmoving components. Followthe oil and filter changeintervals as recommended inthis section of the manual.Failure to comply may resultin equipment or propertydamage.

A major factor in maintaining engineperformance and durability is theproper use of quality engine lubricating

oils used in conjunction with theappropriate oil drain and filter changeintervals. Attempting to extend the oiland filter change interval beyond themanufacturers recommendations maydecrease engine life.

NOTE: It is the ownersresponsibility to correctly followlubricating oil recommendations.If recommendations are ignored,the engine warranty could beaffected.

PACCAR recommends the use ofhigh-quality SAE 15W40 (API CJ-4)heavy-duty engine oil.

The primary PACCARrecommendation is for the use of15W-40 multigrade lubricating oilfor normal operation at ambienttemperatures above 5°F (-15°C).For ambient temperatures below5°F (-15°C) SAE 5W30 may beused, provided it meets API CJ-4oil specifications and biodiesel or

biodiesel blended fuel is not used asfuel for the engine. Using a multigradeoil helps improve engine cranking inlow-temperature conditions, reducesdeposit formation and increasesengine durability.

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New Engine Break-In Oils

PACCAR does not approve the use ofspecial “break-in” engine lubricatingoils for new or rebuilt PACCARengines. It is recommended to usethe same lubricating oil for enginebreak-in that will be used during normaloperation.

Aftermarket Oil Additive Usage

PACCAR does not recommend the useof aftermarket oil additives. Today’shigh-quality engine lubricating oils arevery sophisticated. Most oils alreadycontain precise amounts of additivesblended into the lubricating oil to meetstringent performance requirements.

These oils meet performancecharacteristics that conform to thelubricant industry standards andare sufficient protection when usedaccording to the recommendations.Aftermarket lubricating oil additives arenot necessary to enhance engine oilperformance and may in some casesreduce the oil’s capability to protectthe engine.

Coolant Recommendationsand Specifications

The cooling system in your vehiclewas factory filled with Extended LifeCoolant (ELC) that meets or exceedsall ASTM D 6210 requirements.PACCAR recommends only using a50/50 mixture of distilled water andELC when cooling system serviceis required. A 50/50 mixture of ELCand distilled water will provide freezeprotection down to -34°F (- 36.7°C),which is adequate for most locationsin North America. For extremely coldoperating conditions, a 60/40 mixture(coolant/water ratio) can be used toprovide freeze protection down to-62°F (-52.2°C).

Your engine is also equipped with aCoolant Filter designed to captureand remove harmful deposits from thecooling system to help prolong systemlife.

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Checking Coolant Condition

To ensure the Extended Life Coolant(ELC) in your vehicle always providesmaximum freeze protection, performthe following tests:

1. Check the coolant color at everymaintenance interval. It should bea bright red with no signs of debrisor any oil.

2. Test the freeze point at least twotimes a year. A refractometer ortest strips can be used to measurethe protection level.

3. Keep the cooling system at fulllevels by topping-up using ELCpre-diluted to 50/50 blend.

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Recommended Extended LifeCoolant Suppliers

Brand Name SupplierTRP Authorized PACCAR Engine Dealer

Cooling System Sealing Additives

CAUTION: The use of sealingadditives in the coolingsystem can cause damage tothe engine. Sealing additivescan plug various areas ofthe radiator, EGR systemand oil cooler. The pluggingof the cooling system canhamper heat transfer, causinginternal engine damage. Donot use sealing additives inthe cooling system. The useof sealing additives can:

• Build up in coolantlow-flow areas.

• Plug the radiator and oilcooler.

• Damage the water pumpseal.

Failure to comply may resultin equipment or propertydamage.

Cooling System Soluble Oils

CAUTION: The use of solubleoils in the cooling system cancause damage to the engine.Soluble oils in the coolingsystem can:

• Damage heat transfersurfaces.

• Damage seals and hoses.

Failure to comply may resultin equipment or propertydamage.

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Maintenance Procedures

MaintenanceProcedures

Oil Pan Drain Plug

After draining the oil, discard thewasher and replace with a new coppersealing washer, torque the bolt to 44lb-ft (60 Nm).

Inspection of the Engine OilLevel

NOTE: It takes approximately15 minutes for all the oil to runinto the sump when the engineis ‘warm.’ If the level is checkedimmediately after switching offthe engine, the dipstick willshow a low oil level.

1. Make sure that the vehicle framerail is standing on a flat and levelsurface.

2. Make sure that the vehicle ishorizontal, both lengthwise andcrosswise. Check this carefullyon a vehicle with air suspension.Note that the engine may beinclined up to 4° depending on thevehicle model and wheelbase.

3. Twist the dipstick handle to unlockit, then pull the dipstick out of theholder.

4. Wipe the dipstick clean with alint-free cloth.

5. Place the dipstick back into theholder.

6. Pull the dipstick out again andcheck the oil level. The oil levelshould always be between the 2marks on the dipstick.

7. Reinstall the dipstick and twist tolock it in place.

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1. Engine Oil High Level2. Engine Oil Low Level

Topping Up the Engine Oil1. Top up with oil, if necessary, via

the filler opening. Use the correctgrade in the correct quantity.

2. After topping up, wait 1 minute andcheck the oil level again.

3. Reinstall the oil fill cap and twistto lock it in place.

NOTE: PACCAR recommendsthe use of high-quality SAE15W40 (API CJ-4) heavy-dutyengine oil.

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Replacing Engine Oil Filters

1. full-flow Oil Filter2. centrifugal bypass Oil Filter

Your engine is equipped with a full-flowoil filter and centrifugal bypass oil filter.Both filters are designed to capturecontaminants and remove depositsfrom the oil to prolong the life ofinternal moving components. Alwaysuse quality engine lubricating oils inconjunction with the appropriate oildrain and filter change intervals. Referto “Maintenance Schedule” beginningon page 5-4 for the recommended oiland filter change service interval.

Oil Filter Removal Preparation

1. Disconnect the chassis batterycable at the negative batteryterminal.

CAUTION: Beforebeginning to removeand/or disconnect anycomponents, wait at least5 minutes after the keyswitch is turned OFFfor the aftertreatmentDiesel Emission Fluid(DEF) dosing systemto purge the DEF fromthe system. The DEFsystem purges to preventdamage from freezing.Failure to comply mayresult in equipment orproperty damage.

WARNING: Electricalshock hazard: Neverdisconnect the batteryclamp when the engine is

running. Disconnectingthe battery clamps whilethe engine is running mayresult in death, personalinjury or equipmentdamage from electricalarching or damage toelectrical components.Turn off the engine andplace the ignition switchin the OFF position beforedisconnecting the batteryclamps. Do not place anytools or other materialson top of or close tothe batteries. This cancause a dangerous highcurrent short circuitand, in the worst case, abattery explosion. Keepall objects away fromthe battery terminals.Always break the contactbetween the batteryclamp and the negativeterminal before working

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on the vehicle. Workingon a vehicle while thebattery is connectedmay result in electricalinjury or damage. Alwaysdisconnect the batteryat the negative terminalwhen performing serviceprocedures.

2. Place an oil collection pan directlyunder the oil filter.

Centrifugal Bypass Oil FilterRemoval

1. Remove the cap of the centrifugaloil filter. Use a hexagonal socketto avoid damaging the oil filter cap.

2. Remove the O-ring from the screwcap.

WARNING: Lubricating oilcan cause skin irritation orskin injury. To prevent skininjury, avoid unnecessarycontact with the lubricatingoil. Wear protective clothing,eye wear and gloves whenhandling lubricating oil.

Failure to comply may resultin personal injury.

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Centrifugal Bypass Oil FilterInstallation

1. Lightly lubricate the O-ring (1) withengine oil.

2. Fit the new O-ring (1) onto the cap(2).

3. Mount the centrifugal filter (3) withits top side in the bearing of thescrew cap (2).

4. Check to ensure the centrifugalfilter (3) can rotate freely.

5. Position the screw cap carefullyonto the oil module.

6. Tighten the screw cap by handuntil it reaches the end position.

7. Tighten the screw cap to 354 lb-in(40 Nm). Use a hexagonal socketto avoid damaging the oil filter cap.

Full-flow Oil Filter Removal

1. Unscrew the cap a few turnsand drain the filter housing. Usea hexagonal socket to avoiddamaging the oil filter cap.

2. Remove the cap, with the oil filtercartridge, from the filter housing.Then remove the oil filter cartridgefrom the screw cap.

3. Remove the O-ring from the screwcap.

4. Remove the centrifugal filter.

WARNING: Lubricating oilcan cause skin irritation orskin injury. To prevent skin

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injury, avoid unnecessarycontact with the lubricatingoil. Wear protective clothing,eye wear and gloves whenhandling lubricating oil.Failure to comply may resultin personal injury.

Full-flow Oil Filter Installation

1. Lightly oil the new O-ring.

2. Install a new O-ring onto the screwcap.

3. Install the screw cap, with theoil filter cartridge, onto the filterhousing. Tighten the screwcap to 354 lb-in (40 Nm). Usea hexagonal socket to avoiddamaging the oil filter cap.

After Replacing Oil Filter(s)

1. Reconnect the chassis batterycable at the negative batteryterminal. See Warnings atCentrifugal oil filter removalpreparation.

2. Add approved engine oil SAE15W40 (API CJ-4) to the maximumlevel marked on the dipstick.

3. Start and run the engine for fiveto ten minutes and check for anyoil leaks.

4. Remove oil collection pan anddispose of any spillage properly.

5. Check engine oil level and top upas necessary.

° chassis must be on levelsurface

° wait at least five minutes if theengine has been hot

° pull the dipstick and wipe witha clean, lint free cloth

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° reinsert the dipstick, thenremove and check the oil level

° add approved engine oil SAE15W40 (API CJ-4) to themaximum level marked on thedipstick

Replacing Fuel Filter

WARNING: When removingthe fuel filter, a quantity of fuelwill escape. Do not smoke orallow an open flame in closeproximity. Failure to do socould ignite a fire or cause anexplosion which could resultin serious injury to you and/orbystanders. Failure to complymay result in death, personalinjury, equipment or propertydamage.

NOTE: The fuel filter and thehand pump are located on theleft-hand side of the engine.

Removal

1. Air bleed screw2. Fuel filter housing3. Fuel filter

1. Loosen the fuel tank cap to relieveany pressure in the fuel tank.

2. Clean the fuel filter housing (2)and surrounding area.

CAUTION: Dirt in thefuel system can lead tosignificant damage tothe fuel system. Failureto comply may result inequipment or propertydamage.

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3. Remove the fuel filter (3) byrotating it counter-clockwise. Usea filter wrench to remove.

NOTE: Prevent fuel fromleaking or dripping on thestarter motor.

NOTE: The fuel filtercartridge is a disposablefilter and may not becleaned and reused.Dispose of the filter aschemical waste.

Installation

4. Fuel primer pump knob5. Fuel primer pump

1. Before installing the new fuel filter,fill filter with clean diesel fuel andlightly oil the filter o-ring with fuelor engine oil.

2. Install the new fuel filter (3),rotating it clockwise until the filtero-ring makes contact with the filterhousing (2). Then tighten the filterby hand ¾ of a revolution.

3. Loosen the fuel filter housingair bleed screw (1) by rotating itcounter-clockwise.

4. Loosen the fuel primer pump knob(5) by rotating it counter-clockwise.

5. Operate the primer pump (4) bymoving the knob (5) in and outuntil fuel (without air bubbles)bleeds out of the fuel filter housingair bleed screw (1).

6. With the primer pump knob (5)pushed in, tighten the fuel filterhousing air bleed screw (1).

7. Next, operate the primer pump (4)by moving the knob (5) in and outuntil pumping resistance increasesnoticeably. Then tighten the knobby rotating it clockwise.

8. Check for leakage at the air bleedscrew (1) and fuel filter (3). Tightenif necessary.

WARNING: Check the fuelfilter and air bleed screwfor signs of leakage.Do not smoke or allowan open flame in close

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proximity. Failure to doso could ignite a fire orcause an explosion whichcould result in seriousinjury to you and/orbystanders. Failure tocomply may result indeath, personal injury,equipment or propertydamage.

9. Start the engine and run it at idlespeed for several minutes. Thiswill allow any air in the system toescape. Then turn the engine offand check the system for leakage.

10. Re-start the engine. If the enginedoes not start, or runs erratic,follow the procedure under“Starting After the Fuel Tank HasRun Dry”.

Starting After the Fuel Tank HasRun Dry

The following instructions should onlybe used in emergency situations whenthe fuel tank has run dry. Failure tofollow the starting instructions belowmay damage the starter motor.

4. Fuel primer pump knob5. Fuel primer pump

1. Loosen the fuel primer pump knob(5) by rotating it counter-clockwise.

2. Next, operate the primer pump (4)by moving the knob (5) in and outuntil pumping resistance increasesnoticeably. Then tighten the knobby rotating it clockwise.

3. Operate the starter motor until theengine starts.

NOTE: The maximum timethe starter motor can beswitched on at any giventime is 30 seconds.

4. If the engine does not start withinthis time, allow the starter motorto cool down for at least 1 minutebefore repeating the procedure.

WARNING: Do not loosenany fuel line fittings in orderto bleed the fuel system ofair. The system is underhigh pressure which, whenrelieved, could cause death,personal injury, equipment orproperty damage.

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Replacing Coolant Filter

Your engine is equipped with aCoolant Filter designed to captureand remove harmful deposits fromthe cooling system to help prolongsystem life. Refer to the “MaintenanceSchedule” beginning on page 5-4 forthe recommended coolant filter changeservice interval.

WARNING: Do not removethe radiator cap on a hotengine. It can cause scaldingcoolant to spray out andyou could be burned. If theengine has been operatedwithin the last 30 minutes,be very careful in removingthe radiator cap. Failure tocomply may result in death,personal injury, equipment orproperty damage.

• Protect face, hands, andarms against escapingfluid and steam by

covering the cap witha large, thick rag.

WARNING: Handle coolantand antifreeze carefully.Ethylene glycol antifreeze ispoisonous. Store in originalfluid container only, andalways keep out of the reachof children. Failure to complymay result in death, personalinjury, equipment or propertydamage.

• Also, never remove thecap on the surge tankwhile the engine is stillhot. Wait until the coolanttemperature is below120°F (50°C). Scaldingsteam and fluid underpressure may escape andcause serious personalinjuries.

Removal

1. Slowly loosen the radiator cap torelieve any pressure in the coolingsystem.

2. Close the coolant filter shutoffvalve by rotating it to the “C”position.

3. Clean the coolant filter andsurrounding area.

4. Remove the coolant filter byrotating it counter-clockwise. Usea filter wrench to remove.

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NOTE: A small amount ofcoolant could leak out whenthe filter is loosened. Use asuitable container to catchany drips.

NOTE: The coolant filtercartridge is a disposablefilter and may not becleaned and reused.Dispose of the filter aschemical waste.

5. Remove the O-ring from thecoolant filter housing, if it has notbeen removed already.

Installation

1. Apply a small amount of coolant tothe sealing ring of the new coolantfilter.

2. Install the filter, rotating itclockwise until the sealing ringmakes contact with the filterhousing. Then tighten by hand ½ -¾ of a revolution.

3. Turn the shutoff valve to the Openposition.

4. Reinstall the radiator cap.

5. Start the engine and run at idlespeed for several minutes. Checkfor leaks.

Emergency RepairsReplacing Belts

NOTE: IMPORTANT: Alwaysfit the same type of belts asthe ones replaced.

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Poly V-belt, Coolant Pump Drive andFan DriveRemoval

1. Disconnect the electrical groundwire from the battery.

2. Place a flex-bar with a 15-mmsocket on the automatic belttensioner roller fastener as shown.Rotate the flex-bar as shown inthe diagram to relieve belt tension.

3. With the belt tensioner pressurerelieved, remove the poly V-beltfrom the pulleys.

NOTE: The tensioner canbe temporarily blockedwith a 0.16-0.2 inch (4-5mm) thick pin (bore). Thisfacilitates removal andinstallation of the polyV-belt.

4. After removing the belt, carefullyallow the belt tensioner to springback to the stop (if it had not beentemporarily blocked).

5. Inspect the pulleys for damage,rust, and grease deposits. Cleanor replace as necessary.

Installation

1. Place the new poly V-belt over thepulleys, making certain the beltfalls into all the belt pulley grooves.

2. After installing the belt, carefullyallow the belt tensioner to springback to its normal position. If thetensioner had been temporarilyblocked, relieve tensionerpressure enough to remove

the locking pin, then allow thetensioner to spring back to itsnormal position.

3. Reconnect the electrical groundwire to the battery.

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Removal and Installation—PolyV-belt, Alternator andAir-Conditioning CompressorDriveRemoval

1. Remove the poly V-belt from thefan and coolant pump drive asdescribed in “Poly V-belt, CoolantPump Drive and Fan Drive”“Removal”.

2. Next, place a flex-bar with a15 mm socket on the alternatorand air conditioning compressordrive belt tensioner roller fasteneras shown. Move the bar in thedirection shown to relieve pressureon the belt tensioner.

3. With the belt tensioner pressurerelieved, remove the poly V-beltfrom the pulleys.

NOTE: The tensioner canbe temporarily blockedwith a 0.16-0.2 inch (4-5mm) thick pin (bore). This

facilitates removal andinstallation of the polyV-belt.

4. After removing the belt, carefullyallow the belt tensioner to springback to the stop (if it had not beentemporarily blocked).

5. Inspect the pulleys for damage,rust and grease deposits. Cleanor replace as necessary.

Installation

1. Place the new poly V-belt over thepulleys, positioning the new belt

so that it falls into all the belt pulleygrooves.

2. After installing the belt, carefullyallow the belt tensioner to springback to its normal position. If thetensioner had been temporarilyblocked, relieve tensionerpressure enough to removethe locking pin, then allow thetensioner to spring back to itsnormal position.

3. Reinstall the coolant pump andfan drive poly V-belt as previouslydescribed in “Poly V-belt, CoolantPump Drive and Fan Drive”“Installation”.

4. Reconnect the electrical groundwire to the battery.

Cleaning the Engine

When cleaning the engine, followthe instructions from the vehiclemanufacturer Operator’s Manual andobserve all environmental protectionregulations.

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5


CAUTION: Do not direct wateronto electrical components,plug connectors, seals orflexible hoses on the engine.Water may enter the partcausing electrical damageor contaminating oil. Toprevent damage to enginecomponents, keep the watermoving at all times whilecleaning the engine. Failureto comply may result inequipment damage.

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5

Information

Engine IdentificationEngine Component Locations . . . . . . 6-3EPA Label . . . . . . . . . . . . . . . 6-4

WarrantyUnited States and Canada PACCAR MXEngine Coverage . . . . . . . . . . . 6-5

United States and Canada Fire ApparatusTruck Applications Coverage . . . . . . 6-9

Emission Warranty . . . . . . . . . . 6-13California Emission Control SystemWarranty, On-Highway. . . . . . . . 6-15

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Engine Identification

Engine Identification Engine ComponentLocations

Right Side of Engine

1. Coolant Filter2. Full-flow Oil Filter3. Centrifugal Bypass Oil Filter4. Oil Cooler5. Turbocharger

Left Side of Engine

1. Fuel Filter2. Air Compressor3. Power Steering Pump4. Starter5. Fuel Pump6. Electronic Control Module (ECM)7. Crankcase Vent8. Alternator9. A/C Compressor

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6

Engine Identification

EPA Label

The EPA label provides important factsabout the engine. The EPA label islocated on top of the engine valvecover. The engine EPA label mustnot be changed unless approved byPACCAR.

1. EPA Label Location

The EPA label provides many detailsregarding the engine. Some facts thatare found on the EPA label include thefollowing:

• Fuel rate

• Idle speed

• Maximum rated speed

• Valve lash

• Maximum power rating

• Date of manufacture

• Engine displacement

6-4

6

Warranty

Warranty

United States and CanadaPACCAR MX EngineCoverageProducts Warranted

This warranty applies to new PACCARMX Engines sold and used in theUnited States or Canada and operatedin on-highway applications with oneexception – there is different warrantycoverage for engines used in the fireapparatus truck applications.

The PACCAR MX Engine is warranteddirectly to the first purchaser byPACCAR.

Base Engine Warranty

This warranty covers any failures of theEngine which result, under normal useand service, from a defect in materialor factory workmanship (WarrantableFailure). This coverage begins on thedate of delivery and ends two years or250,000 miles (400,000 kilometers) or6,250 hours, whichever occurs first,after the date of delivery of the Engineto the first purchaser.

Additional coverage is outlined in theEmission Warranty section.

Major Engine Components Warranty

There is an Engine Warranty periodof 60 months, 500,000 miles (800,000kilometers) or 12,500 hours, whicheveroccurs first, after the date of deliveryof the Engine to the first purchaser forthe following Engine parts:

• Cylinder Block Casting

• Main Bearing Bolts

• Cylinder Head Casting

• Cylinder Head Bolts

• Crankshaft

• Camshaft

• Cam Follower Assemblies

• Connecting Rod Assemblies

• Crankshaft Gear

• Camshaft Gear

• Camshaft Idler Gear

• Lube Pump Gear

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6

Warranty

• Flywheel Housing

• Water Pump Housing

• Thermostat Housing

PACCAR Responsibilities

PACCAR will pay for all parts and laborneeded to repair the damage to theEngine resulting from a WarrantableFailure.

PACCAR will pay for the lubricatingoil, antifreeze, filter elements, belts,hoses, and other maintenance itemsthat are not reusable due to theWarrantable Failure. PACCAR will payfor reasonable labor costs for Engineremoval and reinstallation whennecessary to repair a WarrantableFailure.

PACCAR will pay during the baseengine warranty period of two years or250,000 miles (400,000 kilometers) or6,250 hours, whichever occurs first.Reasonable costs for towing a vehicledisabled by a Warrantable Failure tothe nearest authorized repair station.In lieu of the towing expense andin its sole discretion, PACCAR maypay reasonable costs for a mechanic

to travel to and from the location ofthe vehicle when an engine repair isperformed at the site of the failure.

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Warranty

Owner Responsibilities

Owner is responsible for the operationand maintenance of the Engine asspecified in the applicable PACCAROperator’s Manual. Owner is alsoresponsible for providing proof that allrecommended maintenance has beenperformed.

Before the expiration of the applicablewarranty, Owner must notify aPACCAR authorized engine dealer ofany Warrantable Failure and makethe engine available for repair bysuch facility. The Warrantable Failuremust be brought to the attention of aPACCAR authorized engine dealerwithin 30 days of discovery. Ownermust also deliver the Engine to theauthorized engine repair facility duringthe warranty period unless deliver isimpossible because the Engine hasbeen disabled by a Warrantable failure.

Owner is responsible for the costof lubricating oil, antifreeze, filter

elements and other maintenanceitems provided during warranty repairsunless such items are not reusabledue to the Warrantable Failure. Owneris responsible for communicationexpenses, meals, lodging and similarcosts incurred as a result of aWarrantable Failure.

Owner is responsible for non-Enginerepairs and for "downtime" expenses,cargo damage, fines, all applicabletaxes, all business costs and otherlosses resulting from a WarrantableFailure.

Limitations

Your sole and exclusive remedyagainst PACCAR and the SellingDealer arising from your purchase anduse of this Engine is limited to therepair or replacement of “warrantablefailures” at authorized United Statesand Canadian PACCAR EngineDealers, or an authorized PACCAREngine facility where applicable,subject to PACCAR’s time, mileage,and hour limitations of the enginewarranty. The maximum time, mileageand hour limitations of the enginewarranty begin running on the Date ofDelivery to the First Purchaser. Theaccrued time, mileage, or hours iscalculated when the engine is broughtinto an Authorized Dealer for correctionof warrantable failures.

PACCAR is not responsible forfailures or damage resulting fromwhat PACCAR determines to beabuse or neglect, including, but not

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Warranty

limited to: damage due to accident;operation without adequate coolants orlubricants; overfueling; overspeeding;lack of maintenance of lubricating,cooling or intake systems; improperstorage, starting, warm-up, run-in orshutdown practices; unauthorizedmodifications of the Engine. PACCARis also not responsible for failurescaused by incorrect oil or fuel or dieselexhaust fluid or by water, dirt or othercontaminants in the fuel, oil, or dieselexhaust fluid. Failure of replacementparts used in repairs due to the abovenon-warrantable conditions is notwarrantable.

This warranty does not apply toaccessories supplied by the vehicleOEM which are covered by the OEMvehicle warranty.

Failures resulting in excessive oilconsumption are covered for theduration of the coverage or 250,000miles (400,000 kilometers) or 6,250

hours from the date of delivery ofthe Engine to the first purchaser,whichever occurs first. Before a claimfor excessive oil consumption willbe considered, Owner must submitadequate documentation to showthat consumption exceeds PACCARpublished standards.

Failures of belts and hoses supplied byPACCAR are covered for the first yearfrom the date of delivery of the Engineto the first purchaser.

PACCAR does not warrant antifreeze,lubricants, filters, filter elements, orany other part which is considered amaintenance item.

Parts used to repair a WarrantableFailure may be new parts, approvedrebuilt parts, or repaired parts.PACCAR is not responsible forfailures resulting from the use of partsnot approved by PACCAR. A newapproved or rebuilt part used to repaira Warrantable Failure assumes the

identity of the part it replaced and isentitled to the remaining coveragehereunder.

PACCAR is not responsible fordamage or loss resulting from Enginehorsepower/torque upgrades.

PACCAR reserves the right tointerrogate Electronic Control Module(ECM) data for purposes of failureanalysis.

PACCAR DOES NOT COVER WEAROR WEAROUT OF COVEREDPARTS.

THIS WARRANTY AND THEEMISSION WARRANTY SET FORTHHEREINAFTER ARE THE SOLEWARRANTIES MADE BY PACCARIN REGARD TO THESE ENGINES.

THIS LIMITED WARRANTY ISTHE SOLE WARRANTY MADEBY PACCAR AND THE SELLINGDEALER. EXCEPT FOR THE ABOVE

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Warranty

LIMITED WARRANTY, PACCAR ANDTHE SELLING DEALER MAKE NOOTHER WARRANTIES, EXPRESSOR IMPLIED. PACCAR AND THESELLING DEALER EXPRESSLYDISCLAIM ANY WARRANTYOF MERCHANTABILITY ORWARRANTY OF FITNESS FOR APARTICULAR PURPOSE.

PACCAR AND THE SELLINGDEALER SHALL NOT BELIABLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGESINCLUDING, BUT NOT LIMITEDTO: LOSS OF INCOME OR LOSTPROFITS; ENGINE OR VEHICLEDOWNTIME; THIRD PARTYDAMAGE, INCLUDING DAMAGEOR LOSS TO OTHER ENGINES,VEHICLES OR PROPERTY,ATTACHMENTS, TRAILERS ANDCARGO; LOSS OR DAMAGETO PERSONAL CONTENTS;COMMUNICATION EXPENSES;LODGING AND/OR MEAL

EXPENSES; FINES; APPLICABLETAXES OR BUSINESS COSTS ORLOSSES; ATTORNEYS’ FEES; ANDANY LIABILITY YOU MAY HAVE INRESPECT TO ANY OTHER PERSONOR ENTITY.

This warranty gives you specific legalrights, and you may also have otherrights which vary from state to state.

United States and CanadaFire Apparatus TruckApplications CoverageProducts Warranted

This warranty applies to new PACCARMX Engines sold and used in theUnited States or Canada and operatedin fire apparatus truck applications.

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Warranty

Base Engine Warranty

The Base Engine Warranty coversany failures of the Engine whichresult, under normal use and service,from a defect in material or factoryworkmanship (Warrantable Failure).This coverage begins on the date ofdelivery to the first purchaser andends after five years or 100,000miles (160,000 kilometers), whicheveroccurs first.

Additional coverage is outlined in theEmission Warranty section.


PACCAR will pay for all parts and laborneeded to repair the damage to theEngine resulting from a WarrantableFailure.

PACCAR will pay for the lubricatingoil, antifreeze, filter elements, belts,hoses and other maintenance itemsthat are not reusable due to theWarrantable Failure. PACCAR will payfor reasonable labor costs for Engineremoval and reinstallation whennecessary to repair a WarrantableFailure.

PACCAR will pay reasonable costsfor towing a vehicle disabled by aWarrantable Failure to the nearestauthorized repair location. In lieuof the towing expense and at itssole discretion, PACCAR will payreasonable costs for a mechanic totravel to and from the location ofthe vehicle when its engine repair isperformed at the site of the failure.

Owner Responsibilities

Owner is responsible for the operationand maintenance of the Engine asspecified in PACCAR Operator’sManual. Owner is also responsible forproviding proof that all recommendedmaintenance has been performed.

Before the expiration of the applicablewarranty, Owner must notify aPACCAR authorized engine dealer ofany Warrantable Failure and makethe engine available for repair bysuch facility. The Warrantable Failuremust be brought to the attention of aPACCAR authorized engine dealerwithin 30 days of discovery. Exceptfor Engines disabled by a WarrantableFailure, Owner must also deliver theEngine to the repair facility.

Owner is responsible for the costof lubricating oil, antifreeze, filterelements and other maintenanceitems provided during warranty repairs

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Warranty

unless such items are not reusabledue to the Warrantable Failure.

Owner is responsible forcommunication expenses, meals,lodging and similar costs incurred as aresult of a Warrantable Failure.

Owner is responsible for non-Enginerepairs and for downtime expenses,cargo damage, fines, all applicabletaxes, all business costs and otherlosses resulting from a WarrantableFailure.

Owner is responsible for a $100 (U.S.Dollars) deductible per each servicevisit under this plan in the 3rd, 4th, and5th years of base engine warranty.The deductible will not be chargedduring the first two years of the baseengine warranty.

Limitations

Your sole and exclusive remedyagainst PACCAR and the SellingDealer arising from your purchase anduse of this Engine is limited to therepair or replacement of “warrantablefailures” at authorized United Statesand Canadian PACCAR EngineDealers, or an authorized PACCAREngine facility where applicable,subject to PACCAR’s time, mileage,and hour limitations of the enginewarranty. The maximum time, mileageand hour limitations of the enginewarranty begin running on the Date ofDelivery to the First Purchaser. Theaccrued time, mileage, or hours iscalculated when the engine is broughtinto an Authorized Dealer for correctionof warrantable failures.

PACCAR is not responsible forfailures or damage resulting fromwhat PACCAR determines to beabuse or neglect, including but not

limited to: damage due to accident;operation without adequate coolants orlubricants; overfueling; overspeeding;lack of maintenance of lubricating,cooling or intake systems; improperstorage, starting, warm-up, run-in orshutdown practices; unauthorizedmodifications of the Engine. PACCARis also not responsible for failurescaused by incorrect oil, fuel or dieselexhaust fluid or by water, dirt or othercontaminants in the fuel, oil or dieselexhaust fluid. Failure of replacementparts used in repairs due to the abovenon-warrantable conditions is notwarrantable.

This warranty does not apply toaccessories supplied by PACCARwhich are covered by the OEM vehiclewarranty.

Failures resulting in excessive oilconsumption are not covered beyondthe duration of the coverage or100,000 miles (160,000 kilometers) or

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Warranty

6,250 hours from the date of deliveryof the Engine to the first purchaser,whichever occurs first. Before a claimfor excessive oil consumption willbe considered, Owner must submitadequate documentation to showthat consumption exceeds PACCARpublished standards.

Failures of belts and hoses suppliedby PACCAR are not covered beyondthe first year from the date of deliveryof the Engine to the first purchaser.

PACCAR does not warrant antifreeze,lubricants, filters, filter elements, orany other part which is considered amaintenance item.

Parts used to repair a WarrantableFailure may be new parts, approvedrebuilt parts, or repaired parts.PACCAR is not responsible for failuresresulting from the use of parts notapproved by PACCAR. A new orapproved rebuilt part used to repaira Warrantable Failure assumes the

identity of the part it replaced and isentitled to the remaining coveragehereunder.

PACCAR is not responsible fordamage or loss resulting from Enginehorsepower/torque upgrades.

PACCAR reserves the right tointerrogate Electronic Control Module(ECM) data for purposes of failureanalysis.

PACCAR DOES NOT COVER WEAROR WEAROUT OF COVEREDPARTS.

THIS WARRANTY AND THEEMISSION WARRANTY SET FORTHHEREINAFTER ARE THE SOLEWARRANTIES MADE BY PACCARIN REGARD TO THESE ENGINES.

THIS LIMITED WARRANTY ISTHE SOLE WARRANTY MADEBY PACCAR AND THE SELLINGDEALER. EXCEPT FOR THE ABOVE

LIMITED WARRANTY, PACCAR ANDTHE SELLING DEALER MAKE NOOTHER WARRANTIES, EXPRESSOR IMPLIED. PACCAR AND THESELLING DEALER EXPRESSLYDISCLAIM ANY WARRANTYOF MERCHANTABILITY ORWARRANTY OF FITNESS FOR APARTICULAR PURPOSE.

PACCAR AND THE SELLINGDEALER SHALL NOT BELIABLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGESINCLUDING, BUT NOT LIMITEDTO: LOSS OF INCOME OR LOSTPROFITS; ENGINE OR VEHICLEDOWNTIME; THIRD PARTYDAMAGE, INCLUDING DAMAGEOR LOSS TO OTHER ENGINES,VEHICLES OR PROPERTY,ATTACHMENTS, TRAILERS ANDCARGO; LOSS OR DAMAGETO PERSONAL CONTENTS;COMMUNICATION EXPENSES;LODGING AND/OR MEAL

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Warranty

EXPENSES; FINES; APPLICABLETAXES OR BUSINESS COSTS ORLOSSES; ATTORNEYS’ FEES; ANDANY LIABILITY YOU MAY HAVE INRESPECT TO ANY OTHER PERSONOR ENTITY.

This warranty gives you specific legalrights, and you may also have otherrights which vary from state to state.

Emission WarrantyProducts Warranted

This emission warranty applies tonew PACCAR Engines marketedby PACCAR that are used in theUnited States in vehicles designed fortransporting persons or property on astreet or highway.

Coverage

PACCAR warrants to the firstpurchaser and each subsequentpurchaser that the Engine is designed,built and equipped so as to conformat the time of sale by PACCAR withall U.S. Federal emission regulationsapplicable at the time of manufactureand that it is free from defects inmaterial or factory workmanship whichwould cause it not to meet theseregulations within the longer of thefollowing periods: (A) Five years or100,000 miles (160,000 kilometers) ofoperation, whichever occurs first, asmeasured from the date of delivery ofthe Engine to the first purchaser or (B)The Base Engine Warranty.

If the vehicle in which the Engineis installed is registered in the stateof California, a separate CaliforniaEmission Warranty also applies.

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Warranty

Replacement Parts

PACCAR recommends that anyservice parts used for maintenance,repair or replacement of emissioncontrol systems be new or genuineapproved rebuilt parts and assemblies,and that the engine be servicedby an authorized PACCAR Enginedealer. Your vehicle contains air,fuel, and electrical components thatmay affect engine emission controls.The use of non-genuine engine orvehicle replacement parts that are notequivalent to the PACCAR engine orOEM vehicle manufacturer’s originalpart may impair the engine and vehicleemissions control system from workingor functioning effectively, and mayjeopardize your emissions warrantycoverage.

Limitations

Your sole and exclusive remedyagainst PACCAR and the SellingDealer arising from your purchase anduse of this Engine is limited to therepair or replacement of “warrantablefailures” at authorized United Statesand Canadian PACCAR EngineDealers, or an authorized PACCAREngine facility where applicable,subject to PACCAR’s time, mileage,and hour limitations of the engineemission warranty. The maximumtime, mileage and hour limitations ofthe engine emission warranty beginrunning on the Date of Delivery tothe First Purchaser. The accruedtime, mileage, or hours is calculatedwhen the engine is brought into anAuthorized Dealer for correction ofwarrantable failures.

Failures, other than those resultingfrom defects in material or factoryworkmanship, are not covered by this

Warranty. PACCAR is not responsiblefor failures or damage resulting fromwhat PACCAR determines to beabuse or neglect, including, but notlimited to: damage due to accident;operation without adequate coolants orlubricants; overfueling; overspeeding;lack of maintenance of lubricating,cooling or intake systems; improperstorage, starting, warm-up, run-in orshutdown practices; unauthorizedmodifications of the Engine. PACCARis also not responsible for failurescaused by incorrect oil, fuel or dieselexhaust fluid or by water, dirt or othercontaminants in the fuel, oil or dieselexhaust fluid. Failure of replacementparts used in repairs due to the abovenon-warrantable conditions is notwarrantable.

PACCAR is not responsible fornon-Engine repairs, downtimeexpenses, cargo damage, fines, allapplicable taxes, all business costs

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Warranty

or other losses resulting from aWarrantable Failure.

THIS LIMITED EMISSIONWARRANTY IS THE SOLEWARRANTY MADE BY PACCARRELATING TO THE EMISSIONEQUIPMENT. EXCEPT FOR THEABOVE LIMITED WARRANTY,PACCAR MAKES NO OTHERWARRANTIES, EXPRESS ORIMPLIED. PACCAR EXPRESSLYDISCLAIMS ANY WARRANTYOF MERCHANTABILITY ORWARRANTY OF FITNESS FOR APARTICULAR PURPOSE.

PACCAR AND THE SELLINGDEALER SHALL NOT BELIABLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGESINCLUDING, BUT NOT LIMITEDTO: LOSS OF INCOME OR LOSTPROFITS; ENGINE OR VEHICLEDOWNTIME; THIRD PARTYDAMAGE, INCLUDING DAMAGE

OR LOSS TO OTHER ENGINES,VEHICLES OR PROPERTY,ATTACHMENTS, TRAILERS ANDCARGO; LOSS OR DAMAGETO PERSONAL CONTENTS;COMMUNICATION EXPENSES;LODGING AND/OR MEALEXPENSES; FINES; APPLICABLETAXES OR BUSINESS COSTS ORLOSSES; ATTORNEYS’ FEES; ANDANY LIABILITY YOU MAY HAVE INRESPECT TO ANY OTHER PERSONOR ENTITY.

California EmissionControl System Warranty,On-HighwayProducts Warranted

This Emission Control SystemWarranty applies to diesel engines(hereafter, engines) certified withthe California Air Resources Boardbeginning with the year 2010,marketed by PACCAR, and registeredin California for use in on-highwayapplications.

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Warranty

Your Warranty Rights andObligations

The California Air Resources Boardand PACCAR are pleased to explainthe emission control system warrantyon your 2010 and subsequent modelyear diesel engine. In California,new motor vehicle engines mustbe designed, built, and equipped tomeet the State’s stringent anti-smogstandards. PACCAR must warrantthe emission control system on yourdiesel engine for the periods oftime listed below provided there hasbeen no abuse, neglect or impropermaintenance of your diesel engine.

Your emission control system mayinclude parts such as the fuel injectionsystem and engine electronic controlmodule. Also included may be hoses,connectors and other emission relatedassemblies.

If an emission-related part on yourengine is found to have a defect in

material or factory the part will berepaired or replaced by PACCAR.This is your emission control systemdefects warranty.

Manufacturer’s Warranty Coverage

This warranty coverage is provided forfive years or 100,000 miles (160,000)km or 3,000 hours of engine operation,whichever first occurs from the dateof delivery of the engine to the firstpurchaser. Where a WarrantableCondition exists, PACCAR will repairyour engine at no cost to you includingdiagnosis, parts and labor.

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Warranty

Owner’s Warranty Responsibilities

As the engine owner, you areresponsible for the performance of therequired maintenance listed in yourPACCAR Operator’s Manual. Youare responsible for presenting yourengine to an authorized PACCAREngine Dealer as soon as a problemexists. The warranty repairs should becompleted in a reasonable amount oftime, not to exceed 30 days.

PACCAR recommends that you retainall receipts covering maintenance onyour engine, but PACCAR cannotdeny warranty solely for the lack ofreceipts or for the failure to ensurethe performance of all scheduledmaintenance.

As the engine owner, you should alsobe aware that PACCAR may deny youwarranty coverage if your engine or apart has failed due to abuse, neglect,improper maintenance or unapprovedmodifications.

If you have any questionsregarding your warranty rightsand responsibilities, you shouldcontact the vehicle OEM manufacturerat the customer center telephonenumber provided with your vehicleoperating instructions or the CaliforniaAir Resource Board at 9528 TelstarAvenue, El Monte, CA 91731.

A warranted part which is scheduled forreplacement as required maintenanceis warranted up to the first scheduledreplacement point.

Prior to the expiration of the applicablewarranty, Owner must give notice ofany warranted emission control failureto an authorized PACCAR Enginedealer and deliver the engine to suchfacility for repair.

Owner is responsible for incidentalcosts such as: communicationexpenses, meals, lodging incurred byOwner or employees of Owner as aresult of a Warrantable Condition.

Owner is responsible for downtimeexpenses, cargo damage, fines, allapplicable taxes, all business costs,and other losses resulting from aWarrantable Condition.

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Warranty

Emissions Components Statementfor MX Engine (2010) EmissionsEngine Coverage

This list of emission control parts maybe covered by the Emission ControlSystem Warranty under certain failuremodes.

Aftertreatment System

• Electronic Control Unit

• Diesel Oxidation Catalyst

• Diesel Particulate Filter (DPF)

• Selective Catalytic Reduction(SCR) Catalyst

• DPF Air / Fuel Manifold Assembly

• DPF Fuel Injector including air,fuel, and coolant lines

• DPF Fuel Pressure Sensor

• DPF Air Supply Pressure Sensor

• Pressure protection valve andplumbing to DPF Fuel Injector

• DPF Temperature Sensors andSignal Conditioner

• DPF Pressure Sensors

• Pre-SCR Temperature

• Post-SCR Temperature

• NOx Sensor

• Decomposition Pipe and PipeElbows

• Exhaust piping from turbochargerto last aftertreatment device

Diesel Emission Fluid (DEF) System

• DEF Tank, Heater, and associatedplumbing

• DEF Pump Module and associatedplumbing

• DEF Dosing Module with InjectionNozzle and wiring harness

• DEF Level/Temperature Sensor

• DEF Lines and Heating elements

• DEF Line Heater Control Relay

• DEF Tank Heater Coolant ControlValve

• DEF Dosing ECU

Dash Lamp

• DEF Lamp

Crankcase Ventilation System

• Crankcase Ventilation Separatorand associated plumbing

Intake System

• Air Intake Pipe Mixer

• Pressure/Temperature/HumiditySensor before Turbocharger

• Charge Air Cooler and associatedplumbing

• Turbocharger and associatedplumbing

Electronic Control System

• Engine Control Module

• Coolant Temperature Sensor

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Warranty

• Intake Manifold Pressure andTemperature Sensor

• Turbocharger Speed Sensor

• Exhaust Gas Recirculation (EGR)Temperature Sensor

• EGR Differential Pressure Sensorand associated plumbing

• Crankshaft Speed Sensor

• NOx Sensor

• Ambient Temperature Sensor

• Lambda Sensor

• Exhaust Manifold Pressure Sensor

• Temperature after Turbocharger

• Vehicle Speed Sensor

• Engine Oil Temperature Sensor

• Water Pump Speed Sensor

• Fuel Temperature Sensor

• Pressure Sensor after ExhaustThrottle Valve

• Wiring harnesses connected atboth ends to emission warrantycomponents

Exhaust Gas Recirculation System(EGR)

• EGR Valve and associatedplumbing

• EGR Cooler and associatedplumbing

Engine

• Exhaust Manifold

• Exhaust Throttle Valve andplumbing

Fueling System

• Injectors

• Fuel Pumps and associatedengine plumbing

Replacement Parts

PACCAR recommends that anyservice parts used for maintenance,repair or replacement of emissioncontrol systems be new or genuineapproved rebuilt parts and assemblies,and that the engine be servicedby an authorized PACCAR Enginedealer. Your vehicle contains air,fuel, and electrical components thatmay affect engine emission controls.The use of non-genuine engine orvehicle replacement parts that are notequivalent to the PACCAR engine orOEM vehicle manufacturer’s originalpart may impair the engine and vehicleemissions control system from workingor functioning effectively, and mayjeopardize your emissions warrantycoverage.

The owner may elect to havemaintenance, replacement or repair ofthe emission control parts performedby a facility other than an authorized

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Warranty

PACCAR Engine dealer and may electto use parts other than new or genuineapproved rebuilt parts and assembliesfor such maintenance, replacementor repair; however, the cost of suchservice or parts and subsequentfailures resulting from such service orparts will not be covered under thisemission control system warranty,except for Emergency Repairs asdescribed below.


The warranty coverage begins whenthe engine is delivered to the firstpurchaser. Repairs and service will beperformed by any authorized PACCAREngine dealer using new or genuineapproved rebuilt parts and assemblies.PACCAR will repair any of the emissioncontrol parts found by PACCAR tobe defective without charge for partsor labor (including diagnosis whichresults in determination that there hasbeen a failure of a warranted emissioncontrol part).

Emergency Repairs

In the case of an emergency wherean authorized PACCAR Engine dealeris not available, repairs may beperformed by any available repairlocation or by any individual using anyreplacement parts. A part not beingavailable within 30 days or a repairnot being complete within 30 daysconstitutes an emergency. PACCARwill reimburse the Owner for expenses(including diagnosis), not to exceedthe manufacturers suggested retailprice for all warranted parts replacedand labor charges based on themanufacturers recommended timeallowance for the warranty repair andthe geographically appropriate hourlylabor rate. Replaced parts and paidinvoices must be presented at anauthorized PACCAR Engine dealeras a condition of reimbursement foremergency repairs not performed byan authorized PACCAR Engine dealer.

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Warranty

Warranty Limitations

Your sole and exclusive remedyagainst PACCAR and the SellingDealer arising from your purchase anduse of this Engine is limited to therepair or replacement of “warrantablefailures” at authorized United Statesand Canadian PACCAR EngineDealers, or an authorized PACCAREngine facility where applicable,subject to PACCAR’s time, mileage,and hour limitations of the engineemission warranty. The maximumtime, mileage and hour limitations ofthe engine emission warranty beginrunning on the Date of Delivery tothe First Purchaser. The accruedtime, mileage, or hours is calculatedwhen the engine is brought into anAuthorized Dealer for correction ofwarrantable failures.

PACCAR is not responsible forfailures or damage resulting fromwhat PACCAR determines to be

abuse or neglect, including, but notlimited to: damage due to accident;operation without adequate coolants orlubricants; overfueling; overspeeding;lack of maintenance of cooling,lubricating or intake systems; improperstorage, starting, warm-up, run-in orshutdown practices; unauthorizedmodifications to the engine. PACCARis also not responsible for failurescaused by incorrect oil, fuel or dieselexhaust fluid or by water, dirt or othercontaminants in the fuel, oil or dieselexhaust fluid. Failure of replacementparts used in repairs due to the abovenon-warrantable conditions is notwarrantable.

PACCAR is not responsible for failuresresulting from improper repair or theuse of parts which are not genuineapproved parts.

PACCAR is not responsible for thematerial and labor costs of emissioncontrol parts and assemblies replaced

during Scheduled Maintenance ofthe engine as specified in PACCAROperator’s Manuals.

THIS WARRANTY, TOGETHERWITH THE EXPRESS COMMERCIALWARRANTIES ARE THE SOLEWARRANTIES MADE BY PACCARIN REGARD TO THESE ENGINES.

THIS LIMITED EMISSIONSWARRANTY IS THE SOLEWARRANTY MADE BY PACCARAND THE SELLING DEALER.EXCEPT FOR THE ABOVE LIMITEDWARRANTY, PACCAR AND THESELLING DEALER MAKE NOOTHER WARRANTIES, EXPRESSOR IMPLIED. PACCAR AND THESELLING DEALER EXPRESSLYDISCLAIM ANY WARRANTYOF MERCHANTABILITY ORWARRANTY OF FITNESS FOR APARTICULAR PURPOSE.

PACCAR AND THE SELLINGDEALER SHALL NOT BE

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Warranty

LIABLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGESINCLUDING, BUT NOT LIMITEDTO: LOSS OF INCOME OR LOSTPROFITS; ENGINE OR VEHICLEDOWNTIME; THIRD PARTYDAMAGE, INCLUDING DAMAGEOR LOSS TO OTHER ENGINES,VEHICLES OR PROPERTY,ATTACHMENTS, TRAILERS ANDCARGO; LOSS OR DAMAGETO PERSONAL CONTENTS;COMMUNICATION EXPENSES;LODGING AND/OR MEALEXPENSES; FINES; APPLICABLETAXES OR BUSINESS COSTS ORLOSSES; ATTORNEYS’ FEES; ANDANY LIABILITY YOU MAY HAVE INRESPECT TO ANY OTHER PERSONOR ENTITY.

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Index

Index

CCoolant Recommendations andSpecificationschecking coolant condition 5-18cooling system sealingadditives 5-19cooling system soluble oils 5-19recommended extended life coolantsuppliers 5-19

EElectromagnetic Interference(EMI) 4-6general information 4-6system EMI radiation levels 4-7system EMI susceptibility 4-7

Emergency Repairspoly v-belt, coolant pump drive andfan drive 5-31removal and installation—polyv-belt, alternator and

air-conditioning compressordrive 5-32replacing belts 5-30

Engine Braking System 3-6compression brake 3-8compression brake controls 3-8engine compression brake levelswitch operation 3-10

Engine Identificationengine component locations 6-3EPA label 6-4

Engine Operating Range 3-6general information 3-6

Engine Shutdown 4-6before stopping the engine 4-6

Engine Warning Lamps 3-3check engine lamp 3-3check engine lamp (CEL) 3-5diesel emission fluid (DEF)lamp 3-5

diesel particulate filter (DPF)warning lamp 3-4general information 3-3high exhaust system temperature(HEST) warning lamp 3-5stop engine lamp 3-4

FFilter Specifications

general information 5-13

LLubricating Oil Recommendations andSpecificationsgeneral information 5-16

MMaintenance

200,000 mi / 4,500 hours 5-8500,000 mi / 15,000 hours 5-8

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Index

750,000 mi / 22,000 hours 5-8Maintenance Guidelines

general information 5-3Maintenance Procedures

inspection of the engine oillevel 5-20replacing coolant filter 5-29replacing engine oil filters 5-22replacing fuel filter 5-26starting after the fuel tank has rundry 5-28topping up the engine oil 5-21

Maintenance Schedule160,000 mi / 4,800 hours 5-720,000 mi / 600 hours, or 6months 5-540,000 mi / 1,200 hours or 12months 5-740,000 mi / 1,200 hours or 12months (initial) 5-680,000 mi / 2,400 hours or 2years 5-7daily or refueling – maintenancecheck 5-4general information 5-4oil drain intervals 5-3

Maintenance Specificationscoolant recommendations andspecifications 5-17cooling system 5-12engine specifications 5-10filter specifications 5-13fuel recommendations andspecifications 5-13lubricating oil recommendationsand specifications 5-16lubricating oil system 5-11

OOil Pan Drain Plug 5-20Operating Instructions

cold weather starting 4-5general information 4-3normal starting procedure 4-4operating the engine 4-6starting procedure after extendedshutdown or oil change 4-5

Operating the Enginenormal 4-6

SSafety

general safety instructions 1-7illustrations 1-7safety alerts 1-3

WWarranty

California emission control systemwarranty - on-highway 6-15emission warranty 6-13PACCAR MX engine - United Statesand Canada coverage 6-5United States and Canada fireapparatus truck applicationscoverage 6-9

What to do if... 2-3check engine lamp turns on 2-5engine is overheating 2-5engine oil pressure lamp turnson 2-4stop engine lamp turns on 2-3you need roadside assistance 2-3

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Contents Index 7 - Peterbilt Trucks | Peterbilt Motors Company Engine Manuals/PACCAR... · 2014-09-29 · atthetimeofprinting.PACCAR reservestherighttomakechanges ... relieveallpressureintheair,oil,

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